Suzuki Motor is targeting a reduction in vehicle development time by 2030 while developing new powertrain technologies, including a direct-injection turbocharged petrol engine for markets such as India and a range-extender hybrid system with plug-in capability for compact cars.

Suzuki aims to halve new model development time by 2030

Suzuki aims to halve the time required to develop a new vehicle by 2030 by changing how its engineering and manufacturing teams work together. It has also set targets to improve development efficiency by 30% and production efficiency by 50%. The development targets are measured against FY20, while the production-efficiency target uses Suzuki's Manesar plant in India as the benchmark.

The announcement comes as Maruti Suzuki works on a large product programme. The company is targeting a reduction in its vehicle development cycle from 48 months to 36 months and plans to introduce nine new models over three years, including seven SUVs, according to sources familiar with the programme. The two development targets use different baselines.

The programme will require new models to accommodate petrol, CNG, hybrid, flex-fuel and electric powertrains, with each requiring additional engineering, validation, procurement and supplier support. Suzuki plans to bring these functions into vehicle programmes earlier, with planning, design, production, quality and procurement teams working in parallel, supported by greater use of digital engineering and shared modules. The aim is to identify problems earlier and reduce delays between teams.

Maruti Suzuki has also been expanding simulation and virtual testing, seeking earlier supplier involvement and developing components, tooling and manufacturing processes concurrently.

Suzuki develops core technologies in Japan and shares them with Maruti Suzuki, which adapts products for Indian customers and prepares them for production. This arrangement will involve increased workloads as India becomes a larger manufacturing and export base. Suzuki is targeting annual production capacity of about four million vehicles in India from FY30. The company has not disclosed the current group-wide vehicle development period that will serve as the baseline for its 2030 target.

Suzuki developing new turbo-petrol engine for India

Suzuki is also developing a new direct-injection turbocharged engine for growth markets, including India, with the stated aim of increasing performance while reducing fuel consumption.

Referred to as DITC in Suzuki's technology briefing, the engine is among the technologies being prepared for future vehicles, with India specifically identified as one of the markets. Suzuki has not disclosed its capacity, power output or first application.

The development comes as Suzuki works on its hybrid and electric vehicle programmes. The company plans to offer different powertrain technologies according to local energy supplies, infrastructure and customer requirements. In India, where Suzuki is also investing in CNG and biogas, improving petrol-engine efficiency remains part of this strategy.

Suzuki is also researching ways to increase combustion-engine thermal efficiency from around 40% towards 50%. The research builds on work carried out for the Z12E engine and focuses on reducing heat losses through cooling and exhaust systems, engine friction and the energy required to draw air into the engine. Lean combustion, waste-heat recovery and lower-viscosity oil are among the technologies under study, although Suzuki has not specified which will be used in the production DITC engine.

Suzuki confirms range-extender hybrid with plug-in capability

Suzuki has confirmed plans to develop a range-extender system for compact cars as part of its in-house series-hybrid programme with external charging capability. The proposed system, known as REEV Light, will use an electric motor to drive the wheels while an engine generates electricity when required. It will add an external charging connection and a battery sized for the vehicle's intended use.

"For compact cars, we are preparing a series HEV that generates electricity from fuel and drives on the motor, and we will further evolve this series by adding external charging capability and a right-sized battery to create a light range extender," Suzuki said. "It will become a 'REEV Light' that does not carry an oversized battery yet lets you drive without worrying about the remaining charge."

An earlier report identified the Fronx and Baleno as possible applications and said the 1.2-litre three-cylinder Z12E engine could serve as the generator. Suzuki has subsequently confirmed development of its own strong-hybrid powertrain for lower- and mid-level models. However, it has not confirmed whether REEV Light will use the Z12E or be fitted to either model.

A series hybrid generates electricity from fuel without requiring external charging, while a range extender adds the option of charging from an external power source. Suzuki intends to develop both systems together, sharing core platforms and basic designs.

Cost remains a consideration for smaller vehicles. An earlier report said Maruti Suzuki selected the series-hybrid layout partly because it could cost less to produce than a system in which both the engine and electric motor can drive the wheels. Maruti Suzuki uses Toyota-supplied series-parallel hybrid technology in higher-end vehicles, while its own series-hybrid system is intended for smaller models.

Battery size is another consideration. Suzuki aims to match battery capacity to customer requirements without the additional weight and material cost of an oversized pack. With REEV Light, external charging could provide electricity for journeys within the battery's range, while the engine could generate electricity for longer trips.

Suzuki estimates that its compact-car series hybrid could reduce CO₂ emissions by about 29% against its stated 2022 reference, equivalent to roughly 300kg over 10,000km. It has not provided a corresponding emissions estimate, battery capacity or electric-only range for REEV Light.

The range-extender system could provide Maruti Suzuki with another powertrain option as it develops hybrid and electric vehicles alongside petrol and CNG models. Whether REEV Light will be introduced in India, and which model could receive it, has not yet been confirmed.